Biodegradation-enhanced synthetic fiber and methods of making the same

ABSTRACT

The disclosure provides a synthetic biodegradation-enhanced fiber, methods of making such fiber, and articles including such fiber. The fiber includes a polymer material and 0.1 to 10 wt % one or more biodegradation additives at least partially contained within the polymer material. The biodegradation additives enhance the biodegradation rate of the polymer material in a biodegradation environment. The biodegradation additives may comprise at least one of an aliphatic-aromatic ester, a polylactide, an organoleptic, a monosaccharide, an aldohexose or a combination thereof. The synthetic fiber may be micro-denier fiber have a denier of less than or equal to 1, or macro-denier fiber having a denier greater than 1. The synthetic fiber may be siliconized.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Number62/612,789, filed on Jan. 2, 2018, the entire contents of which arehereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to biodegradation-enhancedsynthetic fiber (e.g., biodegradation-enhanced polyester fiber), and tomethods of forming biodegradation-enhanced synthetic fiber, insulationcomprising biodegradation-enhanced synthetic fiber, and articlescomprising biodegradation-enhanced synthetic fiber.

BACKGROUND OF THE INVENTION

Plastics, such as plastics in the polyester family, are industriallymass-produced and used widely throughout the world. For example,thermoplastic or thermoset polymer resins, such as resins includingpolyethylene, are used to form fibers for a myriad of differentapplications, containers for liquids and foodstuff, thermoforming formanufacturing, and in combination with other materials for engineeringapplications. The usage of synthetic plastics is increasing greatly yearover year.

One reason plastic products are so widely used is their ability towithstand the forces of nature. For example, polyethylene polymersconsist of long chains of carbon atoms, which are typically tightlyintertwined, that are difficult to be broken down by microorganisms(e.g., bacteria, fungi or any other microscopic organism) that arenormally responsible for degrading (i.e., biodegrading) material intowater, carbon dioxide, methane and biomass (which is the expiredmicroorganisms). While polyethylene polymers, such as those of thepolyester family, may eventually degrade (e.g., biodegrade), they mayonly do so over a very long period of time. This same characteristicthat makes plastics so attractive has led to serious environmentalproblems.

In recent years, environmental littering and destruction due todiscarded plastic products has occurred at an alarming pace. In theclothing and/or textile industry, for example, it has become anincreasing problem that such products formed by polyester or otherplastic fibers end up in landfills or seawater/waterways. While somebiodegradable plastics have been developed to attempt to mitigate orreduce the disposal problems of plastic products, such materials havenot been suitable for fibers that are used to form high quality clothingand/or textile products. For example, a need still exists for insulativematerial for clothing and/or textile products formed from moreeco-friendly materials.

While certain aspects of conventional technologies have been discussedto facilitate disclosure of Applicant's inventions, the Applicant in noway disclaims these technical aspects, and it is contemplated that theirinventions may encompass one or more conventional technical aspects.

In this specification, where a document, act or item of knowledge isreferred to or discussed, this reference or discussion is not anadmission that the document, act or item of knowledge or any combinationthereof was, at the priority date, publicly available, known to thepublic, part of common general knowledge, or otherwise constitutes priorart under the applicable statutory provisions; or is known to berelevant to an attempt to solve any problem with which thisspecification is concerned.

SUMMARY OF THE INVENTION

Briefly, the present disclosure satisfies the need for improved fiberwith beneficial degradable qualities. In various embodiments, theinventive fiber lends itself toward use in insulation that demonstratesimproved biodegradation without undesirably decreasing the strengthand/or insulative qualities of the insulation.

The present invention may address one or more of the problems anddeficiencies of the art discussed above. However, it is contemplatedthat the invention may prove useful in addressing other problems anddeficiencies in a number of technical areas. Therefore, the claimedinvention should not necessarily be construed as limited to addressingany of the particular problems or deficiencies discussed herein.

In a first aspect, this disclosure provides a syntheticbiodegradation-enhanced fiber. The fiber may comprise a polymer material(such as a polyester), and less than or equal to 10 wt % of abiodegradation additive that enhances the biodegradation rate of thepolymer material. In some embodiments, the syntheticbiodegradation-enhanced fiber may have a denier of 1 or less. In someembodiments, the synthetic biodegradation-enhanced fiber may have adenier of greater than 1. In some embodiments, the syntheticbiodegradation-enhanced fiber may be siliconized.

In a second aspect, this disclosure provides insulation materialcomprising the biodegradation-enhanced synthetic fiber of the firstaspect.

In a third aspect, this disclosure provides an article comprising thesynthetic fiber of the first aspect, or the insulation material of thesecond aspect.

In a fourth aspect, this disclosure provides a method of making thesynthetic biodegradation-enhanced fiber of the first aspect, theinsulation material of the second aspect, and/or the article of thethird aspect. The method of making the synthetic biodegradation-enhancedfiber, insulation material and/or article may comprise mixingbiodegradation particles and a polymer material to form abiodegradation-enhanced polymer mixture, and extruding thebiodegradation-enhanced polymer mixture into a fiber form. In someembodiments, the synthetic biodegradation-enhanced fiber may have adenier of 1 or less. In some embodiments, the syntheticbiodegradation-enhanced fiber may have a denier of greater than 1. Insome embodiments, the method may include performing one or moreadditional processing steps, such as siliconizing the syntheticbiodegradation-enhanced fiber.

Certain embodiments of the presently-disclosed syntheticbiodegradation-enhanced fiber, insulation and articles comprising thesynthetic biodegradation-enhanced fiber, and methods of making thesynthetic biodegradation-enhanced fiber have several features, no singleone of which is solely responsible for their desirable attributes.Without limiting the scope of the synthetic biodegradation-enhancedfiber, insulation, articles, and methods as defined by the claims thatfollow, their more prominent features will now be discussed briefly.After considering this discussion, and particularly after reading thesection of this specification entitled “Detailed Description of theInvention,” one will understand how the features of the variousembodiments disclosed herein provide a number of advantages over thecurrent state of the art. For example, in some embodiments, thesynthetic biodegradation-enhanced fiber provides improved biodegradationproperties, thereby lending itself toward “environmentally friendly”fibers, monofilaments, fill, yarn, woven and nonwoven materials (e.g.,insulation materials), articles (e.g., apparel, footwear, bedding,fabrics, mechanical belts and industrial products) and/or textiles.Embodiments of the synthetic biodegradation-enhanced fiber may bemicro-denier or macro-denier synthetic (e.g., polyester) fiber withimproved biodegradation properties, that may maintain, inter alia, asilky hand feel and heightened water repellency during normal use (e.g.,before being discarded in a microbial biodegradation environment, suchas in a landfill or seawater).

These and other features and advantages of this invention will becomeapparent from the following detailed description of the various aspectsof the invention taken in conjunction with the appended claims and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will hereinafter be described in conjunction withthe following drawing figures, which are not necessarily drawn to scalefor ease of understanding, wherein the same reference numerals retaintheir designation and meaning for the same or like elements throughoutthe various drawings, and wherein:

FIG. 1 is a side perspective view of a container with a mixture ofbiodegradation particles/additives and a polymer material according tocertain embodiments of the present disclosure;

FIG. 2 is side view of a synthetic biodegradation-enhanced fiberaccording to certain embodiments of the present disclosure;

FIG. 3 is an enlarged view of a portion of a pellet embodimentcontaining a mixture of the polymer material and biodegradationparticles;

FIG. 4 is a cross-sectional view of a portion of the syntheticbiodegradation-enhanced fiber of FIG. 2; and

FIG. 5 is cross-sectional view a siliconized syntheticbiodegradation-enhanced fiber according to certain embodiments of thepresent disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the present inventions and certain features, advantages, anddetails thereof, are explained more fully below with reference to thenon-limiting embodiments illustrated in the accompanying drawings.Descriptions of well-known materials, fabrication tools, processingtechniques, etc., are omitted so as to not unnecessarily obscure theinventions in detail. It should be understood, however, that thedetailed description and the specific example(s), while indicatingembodiments of the inventions, are given by way of illustration only,and are not by way of limitation. Various substitutions, modifications,additions and/or arrangements within the spirit and/or scope of theunderlying inventive concepts will be apparent to those skilled in theart from this disclosure.

Biodegradation is the degradation, disintegration, decay, breakdown ortransformation of a material into innocuous products, particularlywater, carbon dioxide, methane and biomass, by the action of livingthings, particularly microorganisms (e.g., bacteria, fungi or any othermicroscopic organisms) and enzymes secreted/produced thereby.Biodegradation may occur aerobically (with oxygen present) oranaerobically (without oxygen present). Decomposition of biodegradablesubstances may include both biological and abiotic steps.

In a first aspect, the invention provides a biodegradation-enhancedsynthetic fiber comprising:

-   -   polymer material; and    -   less than or equal to 10 wt % biodegradation additive to enhance        the biodegradation rate of the polymer material.

Denier is a unit of measure defined as the weight in grams of 9,000meters of a fiber or yarn. It is a common way to specify the weight (orsize) of the fiber or yarn. For example, traditional polyester fibersthat are 1.0 denier typically have a diameter of approximately 10micrometers. Micro-denier fibers are e those having a denier of 1.0 orless, while macro-denier fibers have a denier greater than 1.0.

The denier of the synthetic biodegradation-enhanced fibers of thepresent disclosure may be micro-denier fibers. For example, in someembodiments, the synthetic biodegradation-enhanced fiber may bemicro-denier fibers with a denier equal to or less than 1. In someembodiments, the synthetic biodegradation-enhanced fibers may bemicro-denier fibers with a denier less than 1.0, within the range of 0.5to 1.0, or within the range of 0.7 to 0.9. In some embodiments, thesynthetic biodegradation-enhanced fiber may be micro-denier fibers witha denier of 0.1 to 1.0 (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8,0.9 or 1.0), including any and all ranges and subranges therein. In someembodiments, the synthetic biodegradation-enhanced fiber may include adenier of 0.5 to 7, such as fibers utilized as staple fibers used asloose fill insulation.

In some embodiments, the biodegradation-enhanced synthetic fiber is afiber with a denier (d) wherein 0.4≤d≤200 (e.g., d is 0.4, 0.5, 0.6,0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0,2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4,3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8,4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2,6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6,7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0,9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10, 11, 12, 13, 14, 15, 16,17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34,35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52,53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70,71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88,89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104,105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118,119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132,133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146,147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160,161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174,175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188,189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, or 200 denier),including any and all ranges and subranges therein.

In some embodiments, the synthetic biodegradation-enhanced fibers aremacro-denier fibers with a denier that is greater than 1.0 and less thanor equal to 15.0, (for example, in some embodiments, the synthetic fiberhas a denier of 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1,2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5,3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9,5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3,6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7,7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 10.1,10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 10.0, 11.1, 11.2, 11.3,11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5,12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7,13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9or 15.0), including any and all ranges and subranges therein (e.g., 1.1to 15.0, 1.1 to 12.0, 1.1 to 10.0, 1.1 to 8.0, 1.1 to 6.0, 1.1 to 5.0,1.1 to 4.0, 1.1 to 3.0, 1.1 to 2.0, etc.).

In some embodiments, the biodegradation-enhanced synthetic fiber ismacro-denier monofilament fiber. In some embodiments, the denier of thebiodegradation-enhanced synthetic monofilament fiber may be within therange of 3 to 1,000 (e.g., 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100,105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170,175, 180, 185, 190, 195, 200, 225, 250, 275, 300, 325, 350, 375, 400,425, 450, 475, 500, 525, 550, 575, 600, 650, 700, 750, 800, 850, 900,950 or 1,000), including any and all ranges and subranges therein (e.g.,3 to 1,000, 3 to 600, 3 to 300, 3 to 200, 3 to 150, 3 to 75, 3 to 40, 3to 30 or 3 to 20, etc.).

In some embodiments, the biodegradation-enhanced synthetic fiber may bemonofilament fiber with a thickness (diameter) within the range of 0.5mm to 6 mm (e.g., 0.5, 0.55, 0.6, 0.65, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2,1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6,2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0,4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4,5.5, 5.6, 5.7, 5.8, 5.9, or 6.0 mm), including any and all ranges andsubranges therein (e.g., 0.5 to 5 mm, 0.5 to 4 mm, 0.5 to 3 mm, 0.5 to 2mm, 0.5 to 1.5 mm, 0.5 to 1.4 mm, 0.5 to 1.3 mm, 0.5 to 1.2 mm, 0.5 to1.1 mm, 0.5 to 1.0 mm, 0.5 to 0.9 mm, 0.5 to 0.8 mm, 0.5 to 0.7 mm,etc.).

In some embodiments, the biodegradation-enhanced fibers arebiodegradation-enhanced synthetic fibers. Persons having ordinary skillin the art are readily familiar with many synthetic fibers, and it iswell within their purview to select an appropriate synthetic fiberdepending on desired properties of the textile, fill, batting and/orarticle within which it is intended to be employed. Embodiments of theinventive biodegradation-enhanced fibers can comprise any syntheticfiber known in the art as being conducive to the preparation of textilematerials. In some embodiments, nonexclusive syntheticbiodegradation-enhanced fibers that may be used in the invention areselected from nylon, polyester, polypropylene, polylactic acid (PLA),poly(butyl acrylate) (PBA), polyamide (e.g., nylon/polyamide 6.6,polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10, etc.),acrylic, acetate, polyolefin, rayon, lyocell, aramid, spandex, viscose,and modal fibers, and combinations thereof. In particular embodiments,synthetic biodegradation-enhanced fibers comprise polyesterbiodegradation-enhanced fibers. For example, in some embodiments, thepolyester is selected from poly(ethylene terephthalate) (PET),poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate),poly-1,4-cyclohexelyne dimethylene (PCDT), polytrimethyleneterephthalate (PTT), and terephthalate copolyesters in which at least 85mole percent of the ester units are ethylene terephthalate orhexahydro-p-xylylene terephthalate units. In a particular embodiment,the polyester is polyethylene terephthalate. In some embodiments, thesynthetic biodegradation-enhanced fibers comprise virgin polymermaterial, such as virgin polyester (e.g., PET). In some embodiments, thesynthetic biodegradation-enhanced fibers comprise recycled polymermaterial (e.g., polyester, such a PET), such as post-consumer recycled(PCR) polymer material (e.g., polyester, such as PET).

In some embodiments, the biodegradation-enhanced fibers are dry fibers(i.e., non-slickened, e.g., non-siliconized fibers). In some otherembodiments, the biodegradation-enhanced fibers are slickened fibers,e.g., siliconized fibers.

The synthetic biodegradation-enhanced fiber of the present disclosuremay comprise at least 90 weight % polymer material. For example, in someembodiments, the synthetic biodegradation-enhanced fiber may comprise 90to 99.9 wt% polymer material (e.g., 90.0, 90.1, 90.2, 90.3, 90.4, 90.5,90.6, 90.7, 90.8, 90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6, 91.7,91.8, 91.9, 92.0, 92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7, 92.8, 92.9,93.0, 93.1, 93.2, 93.3, 93.4, 93.5, 93.6, 93.7, 93.8, 93.9, 94.0, 94.1,94.2, 94.3, 94.4, 94.5, 94.6, 94.7, 94.8, 94.9, 95.0, 95.1, 95.2, 95.3,95.4, 95.5, 95.6, 95.7, 95.8, 95.9, 96.0, 96.1, 96.2, 96.3, 96.4, 96.5,96.6, 96.7, 96.8, 96.9, 97.0, 97.1, 97.2, 97.3, 97.4, 97.5, 97.6, 97.7,97.8, 97.9, 98.0, 98.1, 98.2, 98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9,99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9 wt %polymer material), including any and all ranges and subranges therein.

The synthetic biodegradation-enhanced fibers may comprise 0.1 to 15 wt %biodegradation particles or additives (e.g., 0.1, 0.2, 0.3, 0.4, 0.5,0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9,2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3,3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7,4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1,6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5,7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9,9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2,10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4,11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6,12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8,13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9, or15.0 weight percent biodegradation particles), including any and allranges and subranges therein (e.g., 0.1 to 10 wt %, 0.5 to 4.5 wt%, 0.1to 3 wt %, 0.5 to 14.5 wt %, etc.).

In some embodiments, the synthetic biodegradation-enhanced fibercomprises 0.1 to 15 vol. % biodegradation particles or additives (e.g.,0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4,1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8,2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2,4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6,5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0,7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4,8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8,9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0,11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2,12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4,13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6,14.7, 14.8, 14.9, or 15.0 vol. %), including any and all ranges andsubranges therein (e.g., 0.1 to 10 wt %, 0.5 to 4.5 wt%, 0.1 to 3 wt %,0.5 to 14.5 wt %, etc.).

In some embodiments, the synthetic biodegradation-enhanced fiber of thepresent disclosure may comprise equal to or less than 10 weight %biodegradation particles or additives. For example, in some embodiments,the synthetic biodegradation-enhanced fiber may comprise equal to orless than 10.0, 9.9, 9.8, 9.7, 9.6, 9.5, 9.4, 9.3, 9.2, 9.1, 9.0, 8.9,8.7, 8.6, 8.5, 8.4, 8.3, 8.2, 8.1, 8.0, 7.9, 7.8, 7.7, 7.6, 7.5, 7.4,7.3, 7.2, 7.1, 7.0, 6.9, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9,5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5,4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1,3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, 1.9, 1.8, 1.7,1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3,0.2 or 0.1 wt % biodegradation particles or additives, including any andall ranges and subranges therein.

Embodiments of the inventive biodegradation-enhanced synthetic fiberprovide polymeric fibers within which biodegradation particles oradditive(s) are embedded in polymer material. The biodegradationparticles or additives may themselves be biodegradable and may alsoenhance and/or accelerate the biodegradation of the polymer material ascompared to if the biodegradation particles are not present, asdescribed above. In some embodiments, the biodegradation particles arehomogenously mixed within the polymer material, meaning, the mixture ofpolymer material and biodegradation particles comprised within thesynthetic fiber has a substantially uniform composition (i.e., 90-100%uniform composition, e.g., at least 90.0, 90.1, 90.2, 90.3, 90.4, 90.5,90.6, 90.7, 90.8, 90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6, 91.7,91.8, 91.9, 92.0, 92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7, 92.8, 92.9,93.0, 93.1, 93.2, 93.3, 93.4, 93.5, 93.6, 93.7, 93.8, 93.9, 94.0, 94.1,94.2, 94.3, 94.4, 94.5, 94.6, 94.7, 94.8, 94.9, 95.0, 95.1, 95.2, 95.3,95.4, 95.5, 95.6, 95.7, 95.8, 95.9, 96.0, 96.1, 96.2, 96.3, 96.4, 96.5,96.6, 96.7, 96.8, 96.9, 97.0, 97.1, 97.2, 97.3, 97.4, 97.5, 97.6, 97.7,97.8, 97.9, 98.0, 98.1, 98.2, 98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9,99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% uniformcomposition).

If the biodegradation particles include particles of differingmaterials, the differing biodegradation particles themselves may be of asubstantially uniform composition (i.e., 90-100% uniform composition,e.g., at least 90.0, 90.1, 90.2, 90.3, 90.4, 90.5, 90.6, 90.7, 90.8,90.9, 91.0, 91.1, 91.2, 91.3, 91.4, 91.5, 91.6, 91.7, 91.8, 91.9, 92.0,92.1, 92.2, 92.3, 92.4, 92.5, 92.6, 92.7, 92.8, 92.9, 93.0, 93.1, 93.2,93.3, 93.4, 93.5, 93.6, 93.7, 93.8, 93.9, 94.0, 94.1, 94.2, 94.3, 94.4,94.5, 94.6, 94.7, 94.8, 94.9, 95.0, 95.1, 95.2, 95.3, 95.4, 95.5, 95.6,95.7, 95.8, 95.9, 96.0, 96.1, 96.2, 96.3, 96.4, 96.5, 96.6, 96.7, 96.8,96.9, 97.0, 97.1, 97.2, 97.3, 97.4, 97.5, 97.6, 97.7, 97.8, 97.9, 98.0,98.1, 98.2, 98.3, 98.4, 98.5, 98.6, 98.7, 98.8, 98.9, 99.0, 99.1, 99.2,99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% uniform composition).

In some embodiments, within the synthetic biodegradation-enhanced fiber,the biodegradation particles may be, for example, completely or at leastpartially covered by the polymer material. In some embodiments, at least25% of the biodegradation particles present (e.g., greater than 25, 26,27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44,45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62,63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80,81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, or 95%) may beat least partially uncovered by the polymer material and/or at leastpartially exposed at an exterior surface of the polymer material. Insome embodiments, at least 50% of the biodegradation particles withinthe biodegradation-enhanced synthetic fiber may be at least partiallyuncovered or exposed at an exterior surface of the polymer material.

The biodegradation particles or additive may include at least oneorganic compound. The biodegradation particles or additive may includeat least one of an aliphatic-aromatic ester, a polylactide, anorganoleptic, a monosaccharide, an aldohexose or a combination thereof.In some embodiments, the biodegradation additive may include at leastone aliphatic-aromatic ester, at least one polylactide (PLA), at leastone organoleptic, at least one monosaccharide, and at least onealdohexose. In some embodiments, the aliphatic-aromatic ester and/or thepolylactide may act to bond at least one other biodegradation additivecomponent to the polymer material (e.g., a polyester). For example, thealiphatic-aromatic ester and/or the polylactide may be a carrier resinfor the other component(s) of the biodegradation additive. In someembodiments, the aliphatic-aromatic ester, and/or the polylactide mayact a hydrolysis component to increase the hydrolytic quality of thepolymer material and the fiber as a whole. The aliphatic-aromatic ester,polylactide and/or the polymer material chains may be split viahydrolysis by water, such as due to the scission of an ester bond. Thealiphatic-aromatic ester and/or the polylactide (e.g., within thepolymer material of the fiber) may facilitate acid hydrolysis, waterhydrolysis and/or alkaline hydrolysis of the polymer material bychemical and/or enzymatic treatment. The aliphatic-aromatic ester and/orthe polylactide (e.g., within the polymer material of the fiber) mayalso be susceptible to biological attack via an enzymatically catalysedhydrolysis of ester, amide or urethane bonds.

In some embodiments, the aliphatic-aromatic ester comprisespoly[(1,4-butylene terephthalate)-co-(1,4-butylene adipate)](poly[(tetramethylene terephthalate)-co-(tetramethylene adipate)])(BTA). The aliphatic-aromatic ester component of the biodegradationadditive may be formed at least one aliphatic dicarboxylic acid or esterthereof, at least one diol (such as, and not limited to, 1,4-butanedioland at least one polyfunctional aromatic acid (such as, and not limitedto, furan dicarboxylic acid) or ester thereof. The aliphatic-aromaticester component may have more than 60 mol percent aromatic acid content.In some embodiments, the aliphatic-aromatic ester component of thebiodegradation additive may comprise an acid component (e.g., comprisingan aromatic carboxylic acid and an aliphatic acid (e.g., azelaic acid)and a diol component (e.g., selected from the group consisting of C3, C4and C6 diols). In some embodiments, the aliphatic-aromatic estercomponent of the biodegradation additive may comprise a polymerizationreaction product of a dihydric alcohol, and an aromatic dicarboxycompound (e.g., an aromatic dicarboxylic acid, aromatic dicarboxylic(C1-3)alkyl ester, or a combination thereof), and an adipic acid.

The polylactide (PLA) component of the biodegradation additive may beone or more bioactive thermoplastic aliphatic polyester (e.g., derivedfrom a renewable resource). In some embodiments, the polylactidecomponent may comprise poly-L-lactide (PLLA), poly-D-lactide (PDLA),poly(L-lactide-co-D,L-lactide) (PLDLLA). As in known on the art, PLA mayprimarily degrade via abiotic hydrolysis. For example, degradation ofPLA may occur in stages, the first being diffusion of water into thematerial, hydrolysis of ester bonds and lowering of molecular weightfollowed by intracellular uptake of lactic acid oligomers andcatabolism. However, many differing microorganisms may also degrade PLA,such as proteases, actinomycetes, fungus and/or compost microorganisms.

The organoleptic component of the biodegradation additive may beconfigured to attract microorganisms present in an environment suitablefor biodegradation that degrade (or cause degradation), or attract othermicroorganisms that degrade (or cause degradation), of the polymermaterial (and potentially the components biodegradation additiveitself). For example, the organoleptic component of the biodegradationadditive may be configured to attract one or more of the exemplarymicroorganisms discussed below. The organoleptic component of thebiodegradation additive is configured to stimulate one or more senseorgan of microorganisms (such as a taste, color, odor, or feel) toattract the microorganisms to the biodegradation-enhanced syntheticfiber and accelerate biodegradation.

In some embodiments, the organoleptic component of the biodegradationadditive may comprise cultured colloids and natural or manmade fibers.The organoleptic component may comprise organoleptic organic chemicalsas swelling agents i.e. natural fibers, cultured colloids,cyclo-dextrin, polylactic acid, etc. In some embodiments, theorganoleptic component of the biodegradation additive may comprise a3,5-dimethyl-pentenyl-dihydro-2(3H)-furanone isomer mixture. Theorganoleptic component nay be in the range equal to or greater than0-20% by weight of the biodegradation additive. In some embodiments, theorganoleptic component agent is 20-40%, 40-60%, 60-80% or 80-100% byweight of the total biodegradation additive.

The monosaccharide (and/or a polysaccharide) and/or aldohexosecomponents of the biodegradation additive may act as food or consumablematerial for the microorganisms to attract microorganisms and/ormaintain microorganism activity that, ultimately, causes the polymermaterial of the fiber (and thereby the fiber itself) to be broken down.In some embodiments, the monosaccharide may be glucose. In someembodiments, the monosaccharide may be D-glucose, D-galactose, andD-mannose. In some embodiments, the monosaccharide is D-glucose. In someembodiments, the monosaccharide and/or aldohexose components may bebonded to monomers of the polymer material of the fiber. In someembodiments, during formation of the fiber, at least some of themonosaccharide and/or aldohexose components may be substituted into thepolymer.

The biodegradation particles or additive may facilitate or effectuaterapid biodegradation of the fiber (i.e., the polymer material thereof),even in an anaerobic environment. Specifically, the biodegradationadditive may assist microorganisms in breaking down the polyester intoCO₂, H₂O, CH₄, and biomass (which are the expired microorganisms) at asignificantly faster rate than as compared to without the additives. Forexample, the biodegradation additive may allow initial microorganisms(or microbes) to consume C—C bonds within the polymer material at amacromolecular level which results in the consumption of the bonds. Theinitial microorganisms may thereby from indentations, caves, cavities orother open areas that extend into the polymer material of the fiber. Inthis way, the additives and the initial microorganisms create a greateror increased exposed surface area of the polymer, allowing plastophilicmicrobes to attach themselves thereto within the openings of the polymer(rather than only on the exterior surface of the polymer). Thebiodegradation rate of the polymer material is thereby increased oradvanced.

However, the biodegradation additive may increase the biodegradationrate of the polymer material, as compared to the biodegradation ratethereof without the additive, in diverse ways. For example, the additivemay increase the hydrolysis/condensation stage of the biodegradation ofthe fiber, the acidogenesis stage of the biodegradation of the fiber,the acetogenesis stage of the biodegradation of the fiber, themethanogenesis stage of the biodegradation of the fiber, or acombination thereof. As noted above, the biodegradation additive mayincrease the hydrolytic quality of the fiber (or polymer material).Hydrolysis may tend to break down the chains of the polymer material,and thereby cause condensation (i.e., the build-up of water). Thehydrolysis/condensation stage of the fiber/polymer material, effectuatedor more rapidly effectuated by the biodegradation additive, may breakdown the polymer material of the fiber into various sugars.

In the acidogenesis stage of the biodegradation of the fiber, acidogenicmicroorganisms may breakdown the organic matter or biomass resultingfrom the hydrolysis/condensation stage, other biomass of the polymermaterial and/or the additive. The acidogenic microorganisms (e.g.,fermentative bacteria) may produce an acidic environment while creatingvarious acids, alcohols and volatile fatty acids, such as ammonia, H₂,CO₂, H₂S, short volatile fatty acids, carbonic acids, trace amounts ofother byproducts, or a combination thereof. The acidogenicmicroorganisms may thereby produce partially-broken down biomass of/fromthe polymer material.

During the acetogenesis stage of the biodegradation of the fiber,microorganisms may further breakdown the biomass of/from the polymermaterial in to acetic acid, carbon dioxide, hydrogen, or a combinationthereof. For example, acetogenesic microorganisms, such as acetogens,may convert the biomass into acetate from carbon and other energysources. The acetogenesic microorganisms or acetogens may break down thebiomass to a point to which methanogenic microorganisms can utilize muchof the remaining polymer material. For example, during themethanogenesis stage of the biodegradation of the fiber, methanogenicmicroorganisms or methanogens may breakdown the biomass of/from thepolymer material (and potentially some of the intermediate products fromhydrolysis and acidogenesis stages) into methane, water, and carbondioxide, or a combination thereof. In some embodiments, the methanogenicmicroorganisms may utilize acetic acid and carbon dioxide (the two mainproducts from the hydrolysis/condensation stage, acidogenesis stage andacetogenesis stage) to create methane in methanogenesis. For example,the methanogens may utilize CO₂ and H₂ to form CH₄ and H₂O. As anotherexample, the methanogens may utilize CH₃COOH to form CH₄ and CO₂. Whilethe CO2 may be converted into methane and water through the reaction,the main mechanism to create methane in methanogenesis may be the pathinvolving acetic acid. In some embodiments, the acetic acid path maycreate methane and CO₂. Further, as the biomass of the fiber/polymermaterial dissipates, the microorganism themselves may die off andthereby create further biomass.

In some embodiments, the synthetic biodegradation-enhanced fibers of thepresent disclosure more quickly biodegrade as compared to fibers havingsimilar compositions but lacking the biodegradation particles. Forexample, the synthetic biodegradation-enhanced fibers of the presentdisclosure may fully biodegrade (e.g., be converted to water, carbondioxide, methane and biomass or a combination thereof) within 10 yearswhen disposed in an environment suitable for biodegradation (aerobic oranaerobic), such as in a landfill, compost pile/facility,seawater/waterway or other bioactive environment/material that includesmicroorganisms that will break down the polymer of the fibers.

In some embodiments, the synthetic biodegradation-enhanced fibers of thepresent disclosure may fully biodegrade within about 9.5, 9, 8.5, 8,7.5, 7, 6.5 or 6 years when disposed in an environment suitable tobiodegradation (i.e., includes microorganisms that consume or otherwisebreak down the materials of the synthetic fiber into water, carbondioxide, methane or a combination thereof. In some embodiments, at least25% by mass of the synthetic biodegradation-enhanced fibers of thepresent disclosure may biodegrade within about 3, 2.5, 2 or 1.5 yearswhen disposed in an environment suitable to biodegradation.

In some embodiments, the synthetic biodegradation-enhanced fiber of thepresent disclosure (or an article comprising the fibers) meets orexceeds the standards for biodegradability as determined according toASTM D6400-12, Standard Specification for Labeling of Plastics Designedto be Aerobically Composted in Municipal or Industrial Facilities, ASTMInternational, West Conshohocken, Pa., 2012, which is herebyincorporated herein by reference).

In some embodiments, the synthetic biodegradation-enhanced fiber of thepresent disclosure may be siliconized. The term “siliconized” is usedherein to refer to a fiber that is coated with a silicon-comprisingcomposition (e.g., a silicone). Siliconization techniques are well knownin the art, and are described, e.g., in U.S. Pat. No. 3,454,422. Thesilicon-comprising composition may be applied using any method known inthe art, e.g., spraying, mixing, dipping, padding, etc. the fiber. Thesilicon-comprising (e.g., silicone) composition, which may include anorganosiloxane or polysiloxane, bonds to an exterior portion of thefiber. The silicon-comprising (e.g., silicone) composition may therebyextend fully about the polymer material and the biodegradation additivescontained at least partially within the polymer material. Thesilicon-comprising (e.g., silicone) composition may be void of thebiodegradation additives.

In some embodiments, the silicone coating is a polysiloxane such as amethylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane,polydimethylsiloxane, or amino modified dimethylpolysiloxane. As isknown in the art, the silicon-comprising composition may be applieddirectly to a fiber, or may be diluted with a solvent as a solution oremulsion, e.g. an aqueous emulsion of a polysiloxane, prior toapplication. Following treatment, the coating may be dried and/or cured.As is known in the art, a catalyst may be used to accelerate the curingof the silicon-comprising composition (e.g., polysiloxane containingSi—H bonds) and, for convenience, may be added to a silicon-comprisingcomposition emulsion, with the resultant combination being used to treatthe synthetic biodegradation-enhanced fiber. Suitable catalysts includeiron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acidssuch as acetates, octanoates, naphthenates and oleates. In someembodiments, following siliconization, the fiber may be dried to removeresidual solvent and then optionally heated to between 65° and 200° C.to cure.

The synthetic biodegradation-enhanced fiber may be crimped or uncrimped.Various crimps, including spiral (i.e., helical) and standard crimp, areknown in the art. The synthetic biodegradation-enhanced fiber may haveany desired crimp.

In some embodiments, the synthetic biodegradation-enhanced fiber is astaple fiber (i.e., a fiber having a standardized length). For example,in some embodiments, the synthetic biodegradation-enhanced fiber is astaple fiber having a length of 5 to 120 mm (e.g., 5, 6, 7, 8, 9, 10,11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28,29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46,47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64,65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82,83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100,101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114,115, 116, 117, 118, 119, or 120 mm), including any and all ranges andsubranges therein (e.g., 8 to 85 mm). In some embodiments, a pluralityof such staple fibers may be combined or provided together. As anotherexample, in some embodiments, the synthetic biodegradation-enhancedfiber is a staple fiber having a length of 8 to 51 mm (and potentiallydeniers of 0.5 to 7) for loose fill insulation.

In some embodiments, the synthetic biodegradation-enhanced fiber is afilament. A filament is a single long threadlike continuous textilefiber/strand. Unlike staple fibers, which are of finite length,filaments are of indefinite length, and can run for yards or miles (ore.g., where employed in yarn, can run the entire length of yarn). Insome embodiments, the filament ranges in length from 5 inches to severalmiles, including any and all ranges and subranges therein. For example,in some embodiments, the filament may be at least 5 inches in length(e.g., at least 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37,38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55,56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73,74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91,92, 93, 94, 95, 96, 97, 98, 99, or 100 inches in length, or any range orsubrange therein). In some embodiments, the filaments may be at least 1foot in length (e.g., at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30,31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48,49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66,67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84,85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 110,120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250,260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390,400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530,540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670,680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810,820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950,960, 970, 980, 990, or 1000 feet in length, or any range or subrangetherein).

Filaments may be created by a process known as extrusion (which can alsobe called melt spinning). For example, in some embodiments, after mixingbiodegradation particles and the polymer material, the resultantbiodegradation-enhanced polymer mixture may be extruded as anbiodegradation-enhanced polymer pellet. Subsequently, depending ondesired biodegradation particle loading, a plurality of pellets,including at least the biodegradation-enhanced polymer pellet, may beextruded into fiber. For example, pellets can be extruded throughwell-known techniques, such as by bringing them to or beyond theirmelting point, thereby forming liquid biodegradation-enhanced polymermixture, then forcing the liquid biodegradation-enhanced polymer mixturethrough a dye called a spinneret. The spinneret often has many smallholes through which the liquid passes. The liquid polymer streams arecooled upon exiting the spinneret, resulting in long strands ofcontinuous synthetic biodegradation-enhanced fibers. The extrudedfilaments may optionally be combined with those of another (e.g., anadjoining) spinneret to increase the number of filaments in a bundle. Abundle of filaments maybe drawn (stretched) to make each filamentthinner, and may optionally be texturized, as described below.

Alternatively, the extruded filaments may not be combined with one ormore other filament and thereby configured/utilized as a monofilament(i.e., a single, continuous synthetic biodegradation-enhanced filament(or strand)). The monofilament fibers may be utilized as single strandfilaments or as a plurality of strands of fiber.

Texturizing techniques may be performed on filament bundles (used, e.g.,in yarn) to disrupt the parallelization of the filaments, and used onmonofilaments to texturize the monofilaments. Such techniques may serve,for example, to add bulk without adding weight, which can make theresultant yarn seem lighter in weight, have improved hand-feel(softness), appear more opaque, and/or have improved temperatureinsulating properties. While any art-acceptable texturizing processesmay be employed, examples of texturizing processes conducive to use inthe invention include crimping, looping, coiling, crinkling, twistingthen untwisting and knitting then deknitting.

In some embodiments, the synthetic biodegradation-enhanced fiber may bevoid of a lubricious additive, such as that disclosed in U.S. Pat. No.3,324,060.

In some embodiments, the synthetic biodegradation-enhanced fibers may beconfigured as high-melt or non-bonding (or non-binder) fibers, such asfibers with a bonding temperature greater than 200° C. Generallyspeaking, high-melt or non-bonding fibers have a bonding temperaturehigher than the softening temperature of other synthetic fibers presentin a fiber mixture. In some embodiments, the syntheticbiodegradation-enhanced fibers may be configured as bonding fibers, suchas fibers with a bonding temperature less than or equal to 200° C.Generally speaking, binder fibers have a bonding temperature lower thanthe softening temperature of other synthetic fibers present in a fibermixture. In some such embodiments, the synthetic biodegradation-enhancedbinder fibers have a bonding temperature of less than or equal to 200°C. In some embodiments, the synthetic biodegradation-enhanced binderfibers have a bonding temperature of 50 to 200° C. (e.g., 50, 51, 52,53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70,71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88,89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104,105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118,119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132,133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146,147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160,161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174,175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188,189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, or 200° C.),including any and all ranges and subranges therein. In some embodiments,the synthetic biodegradation-enhanced binder fibers have a bondingtemperature of 80° C. to 150° C. In some embodiments, the syntheticbiodegradation-enhanced binder fibers have a bonding temperature of 100°C. to 125° C. In some embodiments, the synthetic biodegradation-enhancedbinder fibers comprise low-melt polyester fibers. In some embodiments,the synthetic biodegradation-enhanced binder fibers are bicomponentfibers comprising an exterior and interior (commonly known in the art asa sheath and core), wherein the exterior comprises a material having alower melting point than the interior. In other embodiments, thesynthetic biodegradation-enhanced binder fibers are monocomponentfibers.

In some embodiments, the synthetic biodegradation-enhanced fiberadditionally comprises one or more additional additives. For example, insome embodiments, the synthetic fiber additionally comprises aerogel.For example, in some embodiments, the synthetic fiber additionallycomprises aerogel particles, as in, e.g., the synthetic fiber describedin International Application Publication No. WO 2017/087511. Forexample, in some embodiments, the inventive fiber comprises 0.1 to 15 wt% aerogel particles, including any and all ranges and subranges therein(e.g., 1 to 10 wt %, 0.5 to 4.5 wt%, 1 to 4.5 wt %, 2 to 4.5 wt %,etc.), said aerogel particles having an average diameter of 0.3 to 20μm, including any and all ranges and subranges therein (e.g., 0.8 to 2μm).

Persons having ordinary skill in the art will readily appreciate thatthere are many applications within which the inventive syntheticbiodegradation-enhanced fiber may be advantageously employed. Indeed,embodiments of the synthetic biodegradation-enhanced fiber andinsulation according to the invention find use in many differentindustries. Non-limiting examples include use in: textile fabrics, e.g.,paper machine clothing, porous and/or non-porous textile mechanicalbelts, wet filters/filtration, dry filter/filtration, etc. (where thefiber could be used as, e.g., a monofilament); refrigerated trucks;pipelines (e.g., petrochemical pipelines); aerospace applications (e.g.,aerospace insulation panels); cryogenic storage tanks; fuel cells; carbattery (e.g., electric car battery) protection; mechanical textilebelts (wet; any other fabric, fabric-like or insulative applications,etc. In some embodiments, when configured as a monofilaments (orfilament bundle), the synthetic biodegradation-enhanced fiber andinsulation according to the invention may be utilized as/in electricalcables and cable assemblies, 3D printer filament, fishing line, eyewearretainers, industrial fastening systems, thread, woven or knitted narrowfabrics, interlayer material (e.g., in double wall tanks or the like),braided reinforcement for cables and/or tubing, knitting needle cables,wet/liquid filters (e.g., water filters/filtration), dry/gas filters(air filters), braided ropes and cords, mist eliminators/stackscrubbers, woven flexible conduit, netting, dental applicators,automobile or industrial fabrics, waistbands, brushes/brooms, weatherseals, medical devices, ultra-violet stabilized fabrics, infusion flowreinforcement textiles, hook and loop fastening systems, mesh, whiskerdisks, etc.

In a second aspect, the invention provides insulation materialcomprising the synthetic biodegradation-enhanced fiber.

In some such embodiments, the insulation material may comprise syntheticbiodegradation-enhanced non-binder fibers. In some embodiments, theinsulation material may comprise synthetic biodegradation-enhancedbinder fibers (and potentially synthetic non-biodegradation-enhancedbinder fibers). In some such embodiments, the insulation material may beheat treated so as to melt all or a portion of the binder fibers,thereby forming a thermally bonded insulation. Persons having ordinaryskill in the art will understand that, in such embodiments, althoughbinder fibers are included in the fiber mixture, said fibers may bewholly or partially melted fibers, as opposed to binder fibers in theiroriginal, pre-heat treatment form.

Persons having ordinary skill in the art will appreciate that thebiodegradation-enhanced fiber of the present disclosure may generally beused in place of or in supplement to synthetic or natural fiber used inor as insulation material.

In some embodiments, the insulation material is fabric, fleece, a pad,blowable insulation material, a non-woven web, vertically lapped battingor horizontally lapped batting. In some embodiments, the insulationmaterial is textile insulation material (i.e., insulation material usedin the textile field).

In some embodiments, the insulation material is blowable insulation orfilling material, comprising a plurality of discrete, longitudinallyelongated floccules each formed of a plurality of syntheticbiodegradation-enhanced fibers according to the first aspect of theinvention, the floccules including a relatively open enlarged medialportion and relatively condensed twisted tail portions extending fromopposing ends of the medial portion. For examples, in some embodiments,the insulation material is a blowable floccule insulation as describedin International Application Publication No. WO 2017/058986, whichcomprises the synthetic biodegradation-enhanced fiber.

In some embodiments, the invention provides batting comprising thesynthetic biodegradation-enhanced fiber. In some embodiments, thebatting has a thickness of 1 mm to 160 mm (e.g., 1, 2, 3, 4, 5, 6, 7, 8,9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26,27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44,45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62,63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80,81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98,99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112,113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126,127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140,141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154,155, 156, 157, 158, 159, or 160 mm), including any and all ranges andsubranges therein. In some embodiments, the thickness is less than orequal to 40 mm, e.g., 2 to 40 mm. In some embodiments, the batting has adensity of 1 to 10 kg/m3 (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 kg/m3),including any and all ranges and subranges therein. In some embodiments,the batting range in weights from 25 GSM to 200 GSM.

In some embodiments, the invention provides yarn comprising thesynthetic biodegradation-enhanced fibers woven, knitted, twisted,braided or otherwise combined. Such yarn may be utilized to form abiodegradation-enhanced textile or other biodegradation-enhanced articlefrom the fibers.

Clo (clo/oz/yd²) is a unit used to measure the thermal resistance ofclothing. A value of 1.0 clo is defined as the amount of insulation thatallows a person at rest to maintain thermal equilibrium in anenvironment at 21° C. (70° F.) in a normally ventilated room (0.1 m/sair movement). Typically, above this temperature the person so dressedwill sweat, whereas below this temperature the person will feel cold.Clothing and/or its components can be assigned a do value. Higher doindicates an article is warmer than another article with a comparativelylower clo.

In some embodiments, insulation (e.g. as batting, loose fill, etc.)comprising the synthetic biodegradation-enhanced fiber has a thermalperformance rating of at least 0.80 clo/oz/yd². In some embodiments, theinsulation has a thermal performance rating of at least 1.0 clo/oz/yd².

In a third aspect, the invention provides an article comprising thesynthetic biodegradation-enhanced fiber of the first aspect of theinvention, or the insulation material of the second aspect of theinvention.

In some non-limiting embodiments, the article is an article of footwear(e.g., shoes, socks, slippers, boots), outerwear (e.g. outerweargarments such as a jacket, coat, shoe, boot, pants (e.g., snow pants,ski pants, etc.) glove, mitten, scarf, hat, etc.), clothing/apparel(e.g., shirts, pants, undergarments (e.g., underwear, thermal underwear,socks, hosiery, etc.), sleepwear (e.g., pajamas, nightgown, robe,etc.)), active wear (e.g., clothing, including footwear, worn for sportor physical exercise), sleeping bag, bedding (e.g., comforter), pillow,cushion, pet bed, home good, etc. In some embodiments, the syntheticbiodegradation-enhanced fiber is comprised within at least a part of oneof the articles listed above.

In a fourth aspect, the invention provides a non-limiting method ofmaking the synthetic biodegradation-enhanced fiber or an articlecomprising the synthetic biodegradation-enhanced fiber (e.g., clothing,insulation material, etc.). The method may comprise:

-   -   mixing the biodegradation particles and the polymer material,        thereby forming a biodegradation-enhanced polymer mixture;    -   extruding the biodegradation-enhanced polymer mixture; and    -   optionally performing one or more additional processing steps,        thereby forming the synthetic biodegradation-enhanced fiber or        article.

In some embodiments, the one more additional processing steps mayinclude siliconizing the biodegradation-enhanced fiber. In someembodiments, method may include, for example, obtaining raw, pure or“new” polymer. In some alternative embodiments, the process may make useof recycled or waste polymer (e.g., leftover polymer from otherprocesses or polymer from other products). In some of such embodiments,the method may optionally include purifying the recycled or wastepolymer to remove contaminants from the recycled or waste polymer. Oncecontaminants are removed, the recycled or waste polymer may be combinedwith the biodegradation particles.

The biodegradation-enhanced polymer mixture may be directly extrudedinto fiber. In other embodiments, the biodegradation-enhanced polymermixture may be extruded or otherwise formed into an intermediary product(e.g., pellets) that can later be used to make fiber. Where anintermediary product (e.g., pellet) is made, the intermediary productmay optionally later be mixed with other material (e.g., other polymermaterial or other pellets that comprise a different or furtherbiodegradation particles, or no biodegradation particles) so as tocontrol and achieve a desired loading percent of biodegradationparticles in subsequently-formed fiber.

Embodiments of the inventive method comprise forming fiber, eitherdirectly from the biodegradation-enhanced polymer mixture, or from theintermediary products (e.g., pellets), using appropriate textile fiberproduction methods, as are well known in the art. The textile fiberproduction method may include, for example, melt spinning, wet spinning,dry spinning, gel spinning, electro spinning, and the like as known inthe art. For example, a mixture (e.g., the biodegradation-enhancedpolymer mixture, or a mixture containing the intermediary products—forexample, a mixture comprising melted intermediary products andoptionally one or more other materials) may be extruded throughspinnerets to form continuous filaments. The continuous filaments maythen be manipulated by, for example, drawing, texturizing, crimping,and/or cutting, or another known method in the art, to form fibers inthe most usable form for their final application. The continuousfilaments may be cut to a specific length and packaged into a bale. Thebale may then be sent, e.g., to a yarn spinner that processes the staplefibers into yarn (which could be further processed, e.g., for use inapparel like base layer garments). In some embodiments, the fibers maybe carded and lapped (horizontally or vertically) into non-woveninsulative batting.

In some embodiments, the biodegradable additive is introduced into apolymer material (e.g., polyethylene, such as PET), and, once mixed, thebiodegradation-enhanced polymer mixture may be extruded into pellets,which may be referred to as a “master batch”. Next, the master batch canbe transferred to a manufacturer for extruding (e.g., melt blownspinning). The master batch may be used (e.g., melted and extruded) toproduce the synthetic biodegradation-enhanced fibers. Alternatively, themaster batch may be combined with pellets of other formulations toproduce a desired mixture than can be used to produce the syntheticbiodegradation-enhanced fibers.

Processing steps undertaken to form the syntheticbiodegradation-enhanced fiber or insulation or articles comprising thesynthetic biodegradation-enhanced fiber can differ depending on thefiber that is intended to be formed. For example, in some embodiments,the inventive process forms a continuous filament by, e.g., drawing (andpotentially texturizing and/or adding one or more desired finishchemistries). In some embodiments, the method forms staple fibers by,e.g., drawing, cutting, optionally crimping, and optionally adding oneor more desired finish chemistries. In some embodiments, the methodforms monofilament fibers by, e.g., drawing and winding the filaments assingle, continuous strands. It is contemplated that any desired finishchemistries may be used in accordance with the invention. Finishchemistries are well known in the art and include, e.g., siliconization,durable water repellency treatment, etc.

The synthetic biodegradation-enhanced fibers may form and/or beincorporated into articles (e.g., end products), for example, garments,fabric, insulation, monofilaments, yarn, etc. In some embodiments, thearticles or insulation with the biodegradation-enhanced fiber morequickly biodegrade than similar articles or insulation without thebiodegradation-enhanced fibers. The synthetic biodegradation-enhancedfiber and/or articles or insulation made with the inventive syntheticbiodegradation-enhanced fiber may have a first full or partial (e.g.,25%, 50%, 75%) biodegradation rate BR₁ (e.g., by mass) while syntheticbiodegradation-enhanced fiber and/or articles or insulation made ofnon-biodegradation-enhanced polymer fibers may have a respective secondfull or partial (e.g., 25%, 50%, 75%) biodegradation rate BR₂ that issubstantially slower/smaller than the first biodegradation rate BR₁. Insome embodiments, the first biodegradation rate BR₁ may be at least 50%faster or 100% faster (i.e., twice as fast) than the secondbiodegradation rate BR₂, such as at least 50%, 75%, 100%, 150%, 200%,300%, 400%, 500%, 600%, 700%, 800%, 900%, 1,000%, 1,100%, 1,200%, 1,300%, 1,400% or 1,500% faster that than the second biodegradation rate BR2.

With reference to FIGS. 1-5, an embodiment of a synthetic (e.g.,polyester) biodegradation-enhanced fiber 130 as described in greaterdetail above, and a method of making such a fiber, is shown. The methodmay include obtaining a polymer material 110 (depicted within acontainer 100 as shown in FIG. 1). The polymer material 110, such aspolyester, may be mixed with biodegradation additives or particles 120to form a biodegradation-enhanced polymer mixture, as shown in FIG. 1.The biodegradation particles 120 may thereby be mixed, such assubstantially homogenously, within the polymer material 110. The mixturemay be extruded into fiber 130 (which may be a filament or may be cut tostaple fiber) as shown in FIGS. 2, 4, and 5, or formed into pellets 140as shown FIG. 4, as described in greater detail above and shown in FIGS.2-5. Where the mixture is melt-extruded into pellets, the pellets maysubsequently be extruded into the fibers 130.

An embodiment of the inventive synthetic biodegradation-enhanced fiber130 is illustrated in FIGS. 2, 4, and 5. As shown, the polymer material110 of the synthetic biodegradation-enhanced fiber 130 contains aplurality of biodegradation particles or additives 120 dispersedthroughout the polymer material 110. The biodegradation particles 120may be homogeneously distributed throughout the polymer material 110.Although FIGS. 2-5 show the biodegradation particles 120 completelyembedded into the polymer material 110, it is also contemplated that insome instances the biodegradation particles 120 may be only at leastpartially embedded into the polymer material 110.

As shown in FIG. 4, the synthetic biodegradation-enhanced fiber 130 maycontain a plurality of biodegradation particles 120 dispersed throughoutthe polymer material 110 of the fiber 130. The biodegradation particles120 may be homogeneously distributed throughout the polymer material 110and fiber 130, as shown. As shown in FIG. 4, the biodegradationparticles 120 may be present at the exterior of the polymer material 110(and potentially the fiber 130 itself) so that microorganisms are ableto consume the biodegradation particles 120 and form the caves,cavities, tunnels or apertures within the interior of the polymermaterial 110 to enhance the biodegradation rate thereof, as explainedabove.

As shown in FIG. 5, the fiber 130 may be siliconized such that thesilicon-comprising material 150 may extend about the polymer material110 and the biodegradation particles 120. In this way, microorganismsmay consume or otherwise cause the silicon-comprising material 150 toseparate from the polymer material 110 and the biodegradation particles120 to thereby expose the biodegradation particles 120. Themicroorganisms may thereby be able to consume the biodegradationparticles 120 and form the caves, cavities, tunnels or apertures toenhance the biodegradation rate thereof, as explained above.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprise” (andany form of comprise, such as “comprises” and “comprising”), “have” (andany form of have, such as “has” and “having”), “include” (and any formof include, such as “includes” and “including”), “contain” (and any formcontain, such as “contains” and “containing”), and any other grammaticalvariant thereof, are open-ended linking verbs. As a result, a method orarticle that “comprises”, “has”, “includes” or “contains” one or moresteps or elements possesses those one or more steps or elements, but isnot limited to possessing only those one or more steps or elements.Likewise, a step of a method or an element of an article that“comprises”, “has”, “includes” or “contains” one or more featurespossesses those one or more features, but is not limited to possessingonly those one or more features.

As used herein, the terms “comprising,” “has,” “including,”“containing,” and other grammatical variants thereof encompass the terms“consisting of” and “consisting essentially of.”

The phrase “consisting essentially of” or grammatical variants thereofwhen used herein are to be taken as specifying the stated features,integers, steps or components but do not preclude the addition of one ormore additional features, integers, steps, components or groups thereofbut only if the additional features, integers, steps, components orgroups thereof do not materially alter the basic and novelcharacteristics of the claimed compositions or methods.

All publications cited in this specification are herein incorporated byreference as if each individual publication were specifically andindividually indicated to be incorporated by reference herein as thoughfully set forth.

Subject matter incorporated by reference is not considered to be analternative to any claim limitations, unless otherwise explicitlyindicated.

Where one or more ranges are referred to throughout this specification,each range is intended to be a shorthand format for presentinginformation, where the range is understood to encompass each discretepoint within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present invention have beendescribed and depicted herein, alternative aspects and embodiments maybe affected by those skilled in the art to accomplish the sameobjectives. Accordingly, this disclosure and the appended claims areintended to cover all such further and alternative aspects andembodiments as fall within the true spirit and scope of the invention.

1. A synthetic biodegradation-enhanced fiber comprising: a polymermaterial; and 0.1 to 10 wt % of one or more biodegradation additives atleast partially contained within the polymer material that enhance thebiodegradation rate of the polymer material in a biodegradationenvironment, said biodegradation additive comprising at least one of analiphatic-aromatic ester, a polylactide, an organoleptic, amonosaccharide, an aldohexose or a combination thereof.
 2. The syntheticbiodegradation-enhanced fiber according to claim 1, comprising at least85% of the polymer material.
 3. The synthetic biodegradation-enhancedfiber according to claims 1, wherein the polymer material comprisespolyester.
 4. (canceled)
 5. The synthetic biodegradation-enhanced fiberaccording to claim 1, wherein the biodegradation additive comprises atleast one aliphatic-aromatic ester, at least one polylactide, at leastone organoleptic, at least one monosaccharide and at least onealdohexose.
 6. The synthetic biodegradation-enhanced fiber according toclaim 5, wherein the synthetic fiber is siliconized.
 7. The syntheticbiodegradation-enhanced fiber according to claim 6, wherein thesiliconizing material is void of the one or more biodegradationadditives.
 8. The synthetic biodegradation-enhanced fiber according toclaim 1, wherein the one or more biodegradation additives arehomogenously dispersed within the polymer material.
 9. The syntheticbiodegradation-enhanced fiber according to claim 1, comprising 0.5 to 3wt % of the one or more biodegradation additives.
 10. (canceled)
 11. Thesynthetic biodegradation-enhanced fiber according to claim 1, having adenier of less than or equal to
 1. 12. (canceled)
 13. The syntheticbiodegradation-enhanced fiber according to claim 1, wherein the fibermeets or exceeds the standards for biodegradability as determinedaccording to ASTM D6400-12. 14-18. (canceled)
 19. The syntheticbiodegradation-enhanced fiber according to claim 1, wherein the fiber isa staple fiber having a length of 5 to 120 mm.
 20. (canceled) 21.(canceled)
 22. Insulation material comprising the syntheticbiodegradation-enhanced fiber according to claim
 1. 23. (canceled) 24.An article comprising the synthetic biodegradation-enhanced fiberaccording to claim
 1. 25. The article according to claim 24, whereinsaid article is selected from the group consisting of an outerwearproduct, footwear, clothing, a sleeping bag, bedding and an industrialtextile.
 26. A synthetic biodegradation-enhanced fiber comprising: apolymer material; 0.1 to 10 wt % of one or more biodegradation additivesat least partially contained within the polymer material that enhancethe biodegradation rate of the polymer material in a biodegradationenvironment, said biodegradation additives comprising at least one of analiphatic-aromatic ester, a polylactide, an organoleptic, amonosaccharide, an aldohexose or a combination thereof; and a siliconcoating extending about the polymer material and biodegradationadditives.
 27. The synthetic biodegradation-enhanced fiber according toclaim 26, comprising at least 85% of the polymer material.
 28. Thesynthetic biodegradation-enhanced fiber according to claim 26, whereinthe polymer material comprises polyester.
 29. (canceled)
 30. Thesynthetic biodegradation-enhanced fiber according to claim 26, whereinthe biodegradation additives comprise at least one aliphatic-aromaticester, at least one polylactide, at least one organoleptic, at least onemonosaccharide and at least one aldohexose.
 31. The syntheticbiodegradation-enhanced fiber according to claim 26, wherein: the one ormore biodegradation additives are homogenously dispersed within thepolymer material; the silicon coating is void of the biodegradationadditives; and the synthetic biodegradation-enhanced fiber comprises 0.5to 3 wt % of the one or more biodegradation additives. 32-49. (canceled)50. A method of making the synthetic biodegradation-enhanced fiberaccording to claim 1, said method comprising: mixing the one or morebiodegradation additives and the polymer material, thereby forming abiodegradation-enhanced polymer mixture; and extruding thebiodegradation-enhanced polymer mixture; and optionally performing oneor more additional processing steps, thereby forming the syntheticfiber. 51-57. (canceled)